1,2,2,2,-Tetrachlorethyl acrylate and methacrylate

ABSTRACT

A compound having the formula   WHEREIN X is hydrogen, chlorine or a methyl group; homo and copolymers thereof and flame resistant articles made from such polymers.

United States Patent Hrabak et al.

l,2.2.2,-TETRACHLORETHYL ACRYLATE AND M ETHACRY LATE lnvemors: Franlisek Hrabak; Milos Vacek. both of Prague. Czechoslovakia Assignee: Ceskoslovenska akademie ved No. 3

Narodni, Prague Czechoslovakia Filed: Oct. 27, 1972 Appl No: 301,275

Foreign Application Priority Data Oct. 28 I97] Czechoslovakia r, 7599-7l Oct 28. l97l Czechoslovakia 76U0 7l US. Cl 4. 260/486 H; 260/803 R;Z60/83.51

260/861. 260/863; 260/867; 260/895 H Int. Cl. C07C 69/54 Field Of Search 260/486 H Primary Exuminer- Lorraine A. Weinherger Assistant E.\'aminerPau| J Killos Arlurney. Agent, or FirmMurr;iy Sehufler I57! ABSTRACT A compound having the formula Cl X wherein X is hydrogen. chlorine or a methyl group; homo and copolymers thereof and flame resist-am articlcs made from such polymers.

[3 Claims, N0 Drawings l l.2.2.2.-TETRACHL()RETH YL ACRYLATE AND METH i-\(R\' LATE This invention relates to a new group of tetralialo substituted alkyl esters of mflmonoethy lenically unsaturated carboxylic acids. methods of making the same homoand copolymers thereof and articles made from the polymers.

More particularly. the invention relates to tetrachloroalkyl acrylates and metbacrylates. especially l.21.Z-tetraehoroethyl acrylates and methacrylatcs.

The l1.2.Z-tetraehloroethyl acrylates and methacrylates ha\e the following formula:

wherein X may be hydrogen. chlorine or lower alkyl and preferably X is hydrogen. chlorine or methyl.

Heretofore compounds as above described have not been known. nor have any methods of producing the same or of the homoor eopolymers thereof.

The compounds of the above formula (1) and especially the homoand eopolyniers of 1.2.2.2-tetraehloroethy'l acrylate and methacrylate may be cmploycd as IlUlPCOlfihtlMl hlt. organic glass. noncombustible foamed insulating materials. components of hardenable adhesives. patties analogous to --Dental;- ryl". noncombustible paints in the form of solutions. aqueous emulsions or suspensions. Non-combustible polymers, prepared according to this invention may be substituted for other plastics in most instances where non-combustibility is required.

It is an object of the present invention to provide a novel group of compounds designated as tetrahalo substituted lower alkyl esters of afi-monoethylenically tinsaturated carboxylic acids.

It is another object of the invention to provide a novel group of compounds designated tetrachloroethyl acrylates and methacrylates.

It is still another object of this invention to provide a method of making such compounds and also the homoand copolymers thereof.

It is a further object of this invention to provide noncombustible articles prepared on the basis of such homoand eopolymers.

Further objects and advantages will become more ap parent as the description of the invention proceeds.

Broadly speaking the instant invention includes the provision of a novel class of compounds designated as tetrachloroethyl acrylates and methacrylates. wherein the acrylate or methacrylate moiety thereof may eontain an additional chlorine substituent.

The above described aerylate and methacrylate esters may be prepared by treatment of chloral with an acyl chloride of the formula wherein X is as above described. Either the pure components or solutions thereof may be employed in the reaction. The reaction may be accelerated by the addition of small amounts of mineral acids. for example. concentrated sulfuric acid. hydrochloric acid and by the use of certain salts. for instance. ferric chloride. The reaction can also be carried out in the presence of an organic or inorganic base such as tricthylamine. sodium carbonate and the like. The amount of mineral acid. salt or base used is however. not critical but should be between lero and 5 percent based on the weight of both reactants. usually between 0.0l and 05 percent.

When a buffer is used herein or in the polymerization step. this may for example be sodium bicarbonate. so dium acetate. or sodium dihydrogen phosphate in an amount of between 0.05)? to about 1.0% based on the weight of the total reactants. (hain transfer agents which may be used. usually in an amount of between about 0.l percent and about 2.0 percent based on the total monomer. include carbon tetrachloride. trichloroethylcne. mercaptans. dissopropylxanthogcn distilphide. toluene and the like.

Where the synthesis is carried out in solution. those solvents which are non-reactive with the reactants should be employed. The solvent should preferably be anhydrous. Suitable sol\ents include benlenc. die thylether. tetrachloromethane and the like. The solvent. when one is employed. is uscd in an amount sufficient to form a workable reaction medium. preferably in amounts between 50 percent and I00 percent based on the volume of both reactants.

The compounds of the invention are preferably prepared by adding the reactants to a sufficient volume of reaction medium which can include a suitable liquid solvent. accelator. base. buffer etc. The reactants may be brought into solution form by addition of the solvent. or they may be reacted by the addition thereto of a suitable liquid accelerator. Where the accelerator se lected for use is a mineral salt. it is preferable that the reactants be present in the form of their solution. The reactants and accelerators may be used in anhydrous form and admixed with a suitable stabilizer. such as hydroquinone. The order of addition of the reactants is not critical. although it is preferred that the accelerator. when one is employed. be added to the mixture of solution of reactants. The addition then may be carried out in increments or the total amount of accelerator may be added at once. The reaction is generally exothermic and is advantageously carried out in an ice bath. lt may however. also be carried out at reflux temperatures. A preferred reaction temperature range is from 20 to 60C. The time of reaction will. in part. be determined by the temperature employed. the reactants involved and whether or not an accelerator is used. The ratio of the reactants may be varied over a wide range. although ordinarily the reactants will be employed in about stoichiometric quantities. preferably amounting to 1;] molar.

The homo and copolymers of the novel compounds of the invention may be prepared by free radical polymerization in either bulk. suspension. solution of emulsion systems utilizing therefor procedcures known to the art. Suitable free radical initiators for polymerization homo or copolymerization include the free radical-supplying polymerization. catalysts yielding oxygen under the conditions of polymerization. as represented by the inorganic and organic peroxygen or peroxide compounds. As examples of such compounds. there may be mentioned hydrogen peroxide. metal and alkali metal peroxides such as sodium. potassium. barium and zinc peroxide. diacyl peroxides such as diaeetyl. dihcnzoyl and dilauroyl peroxide. dialkyl peroxides such as di-(tertiaryhuty'll peroxide and di-(tertiary-hutyll hydroperoside. cyclohcxene peroxide. inorganic peroxygen acids such as perboric. persulfurie and peracetic acid and their ammonium. sodium and potassium salts. in addition to redos systems such as potassium or ammonium persulfatesodium hisulfite. ()ther oxygenyielding compounds or sources include atmospheric oxygen. ozone and the like.

Aro type catalysts. i.e.. compounds containing the aZo linkage. may also be employed. As example ot'sueh catalysts there may be mentioned a.u'-azohis-( (2. dimethylvaleronitrile l. or.a'-a/ohis-l wmethyl butyronitrilel. moU-azobisdwethfl butyronitrile). a.a-a7odiisohuty ramide. dimethyl and diethyl. u.a'-a/odiisohutyrate. and the like.

The preferred catalysts effective for the production ofoptimum results are the azo type. which may he employed along with an acti\ator. Some typical activators are amines. mctabisulfitcs. ascorbic acid. Fe salts and many other activators which are well known to those skilled in the art.

The polymerization will generally be carried out at a temperature effective to cause the initiator or catalyst to form free radicals and thus to propagate and main tain the reaction and preferably hetween 20 and 80C: The catalyst may be employed in amounts ranging from 0005 to 5.0 percent by weight hased on the weight of the monomers. at a temperature of about 20 to [C and preferahly 45 to 80 C.

The reaction is preferably carried out in an inert atmosphere. conveniently under a blanket of nitrogen. argon or the like. and at atmospheric pressure. Also anhydrous conditions should he used.

After the polymerization is effected upon completion of the solution and the heating period. the polymer may he obscn ed to precipitate and may he recovered by filtration or e\aporation of the sol\ cut. The foregoing is applicable when emulsion. suspension or solution polymeri/ation is carried out.

It will he understood that in carrying out the process of this in ention. the known surface acti\e agents. protecti\e colloids. plasticizers. thickeners. and other additives may he added to prior to. during or after the po lymerization reaction is completed Anionic. nonionic or cationic emulsify ing agents may be employed. As c\ amples of nonionic agents which may be employed. there may be mentioned the condensation products of a plurality of moles of ethylene oxide with organic com pounds containing at least 8 carbon atoms and a reacthe hydrogen atom such as the water insoluble carbotylic and sult'onic acids. alcohols. tliiols. phenols. hydrosy carho\ylic acids. carbo\y and sulfonic acid amides. primary and secondary amines and hydrosyalky la mines. As specific c\amples of such nonionic agents there may he mentioned the reaction products of l mole of nonylphcnol with J to 100 F0. lmoles ethylene o\ide l. l mole of castor oil with 20 E.().. 1 mole tall oil with ltl I.().. l mole of olcyl alcohol with 20 F.().. l mole ot'dodeeyl mercaptan with 9 EU. I mole of soybean oil amine with 10 E.().. l mole of rosin amine with 32 mole of cocoanut fatty acid amine with 7 EU. I mole of dinonyl phenol with l5 BO. l mole of oxo trideeyl alcohol with 12 E.().. Pluronic L63 and the like.

Suitahle anionic surface active agents include the sulfonic acids. sulfate esters. and phosphate esters [particularly the primary and secondary phosphate esters and mixtures thereof) of the above mentioned nonionic surface active agents as disclosed. for example, in US. Pat. Nosv 3.004.056 and 3.004.057. Other such anionic surface active agents include alkylaryl sulfonic acids such as dodecylhcnzene sulfonic acid. alkyl sulfates such as sodium M-methyltaurides of higher if to C fatty acids. and isothionates such as sodium N- methylisothionate esters of higher (Cm to C2). fatty acids.

Protective colloids and/or thickening agents may also be employed if desired such as polyvinyl alcohol, copolymers such as the copolymer of vinyl methyl ether and maleic anhydride, hydroxyethyl cellulose. carhoxymethyl cellulose. natural gums and colloidal materials and the like. Viscosities of up to 80.000 cps. or more may therehy he obtained when required.

The order of addition of the monomers catalyst. emulsifier where employed. activator etc.. is not criti cal. The monomers and catalyst. etc. may be added in increments or otherwise. It is preferred that a liquid medium he prepared from all ofthe monomers. catalyst and additional agents and that thereafter polymerization he initiated. Polymerization is effected through the ethylenically unsaturated linkage in the monomers. i.c.. vinyl polymerization.

When the tetrachloroethyl acrylate or methacrylate is copolyrnerized with another monomer. said other monomer may be selected from among those vinyl. diene and conjugated diene monomers which are operati\e to copolymerize hy the free radical mechanism. The vinyl monomer can he an alkenyl or mono alkenyl aromatic monomer i.e.. diolefin. conjugated diolefin. vinyl aromatic or mono-ethylenically unsaturated monomer. The ratio ofthe monomers in the case of copolymerization may vary from 1:99 to 99:] and preferahly from I to 50:1.

By the term conjugated diene" it is meant to include typically. hut-adiene-IJ; Z-methyl-hutadiene-l.3; 2.3- dimethyl hutadiene-l .3; piperylenc; Z-neopcntyl hutadienc-l.3; and other homologs of butadiene-L3 and in addition. the substituted dienes. such as 2- chlorohutadiene-l.3; lcyano-hutadicne-1.3; the substituted straight chain conjugated pentadienes. the straight-and-branchchain hesadienes. and others. The butadiene-lfi hydrocarbons because of their ability to produce particularly desirable polymeric materials. are preferred eomonomers.

As to the mono olefin any normal alpha olefin having at least 4 carhon atoms and no more than 11 carbon atoms. may he used. the C C olefins being preferred. Branched olefins such as 3 methyl butcne-l. 3-methyl hesene-l. Z-methyl hutene-l. 2.4.4-trimethyl pentenel. Z-methyl pentenel and 3.4.4-trimethyl pcntenc-Z are operative. Among other alpha olefins which are applicable are octenel hesene-l decenel octadecenel. hexadecenel dodecenel tetradecene-l cicosenel. and the like.

By the term monoalkenyl aromatic monomer it is intended to include those monomers wherein an alkenyl group is attached directly to an aromatic nucleus containing about 6 to about 10 carbon atoms. These monomers may include alkyl. alkoxy and/or halo substituted compounds. Typical of these monomers are styrene. p-methylstyrene. a-methylstyrene. a-pdimethyl styrene. a and dbromoviny'l benzene. tr and B-chlorovinyl benzene. a-.m-. or p-mctho\y-\inyl benzene. o-p'diethyl sty renc. p-chlorostyrene. isopropyl styrene. tert-butyl styrene. tt-methyLp-isopropyl styrene. ot-chloro-p-methylstyrene. and tz-p diehlorostyrene and the like. and any mixtures thereof. Vinyl naphthalines may also be used either alone. mixtures thereof or in combination with the styrene monomers. Because of its availability and ability to produce desirable polymers and for other reasons. it is preferred to use styrene as the monoalkenyl aromatic monomer.

The alpha. beta-olefinically unsaturated nitriles or primary amides are preferably the monoolefinically tittsaturated nitriles having from 3 to l carbon atoms such as acry'lonitrile methacrylonitrile. etlnicrylonitrile and the like. Most preferred are acrylonitrile and meth acrylonitrile.

hi the following examples and in the appended claims. all parts and proportions are by weight unless otherwise noted.

The following examples are illustrative and are not to be considered as limiting. Preparation of l.3.2.Z-tetrachloroethyl acry'late:

EXAMPLE 1 In a reactor vessel grams of concentrated sulfuric acid was added to a mixture of 102 grams of anhydrous chloral and 62.6 grams of acryloy'l chloride stabilized with hydroquinone. During the addition of the mixture to the reactor. it was stirred and cooled with ice water. A reaction immediately takes place. After it had ceased the resulting dark product was fractionated under rcduced pressure or partial vacuum. The main fraction was collected in the amount of 107 grants at 63C/0.5 Torr and then distilled five times through a descending condenser up to chromatographic purity. Distillation through an effective column is avoided because of the large loss due to polymerization. Refractive index and density of the fraction were as follows: 21,, 1.424621% L463 df" l.-1I-l7. The composition determined by the elementalanalysis:C 25.95 percent. H [.99 percent and Cl 58.53 percent. A standard calculated for l.2..2.Z-tetrachloroethyl acrylate: C 35.34 percent. H L69 percent and Cl 59.62 percent EXAMPLE 2 Into a vessel a solution consisting of 14.7 grams of chloral and [0.4 grams of acryloy'l chloride in ml of benzene. 0.25 grams of anhydrous FeCl; was added. The reaction starts immediately and continues in the refluxing benzene. After the reaction was completed. the mixture was steam-distilled and the lower layer of the condensate was separated. dried and fractionated under reduced pressure. Chromatographically pure l.21.Z-tetrachloroethyl acrylate was obtained in the amount of 1-1.5 grams.

Preparation of l.21.Z-tetrachloroethyl methacrylate:

EXAMPLE 3 In a reactor vessel anhydrous FeCl l 0.15 gramsl was added to a mixture consisting of 134 grams of anhydrous chloral and )5 grams of methacryloyl chloride. stabilized by hydroquinone. The mixture was stirred and cooled in the reactor in ice water. The reaction occurs quickly and after it had ceased. the resulting dark mixture was fractionated under reduced pressure. The main fraction was distilled at 70C/0.4 Torr in the amount of 202 grams. It was refined by a threefold distillation through a descending condenser to chromatographic purity. Refractive index and density of the fraction was as follows: n,,'-' 1.4856. d 1.4 l 87. d f" 1.381]. By the elemental analysis it was determined: C 28.98 percent. H 2.48 percent and Cl 55.08 percent: calculated for l.11.].Z-tetrachloroethyl methacrylate: C 28.60 percent. H 2.40 percent and Cl 56.30 percent. Preparation of the homoand eopolymers of the products of EXAMPLE 4 A solution of 0.0065 grams of 2.2' azobisisobuty'ronitrile in 5 grams of l.2.Z.3-tctrachloroethyl acry'late (the product of Examples l-Z! was charged into a glass ampoule. and cooled to 7RC. The ampoulc was flushed with nitrogen. sealed and placed into a temperature controlled bath heated to 60C. A colorless. clear and elastic plug of the homo polymer thereof was formed after 20 hours. The plug burns in the flame of a gas burner. however. when removed from the flame. burning of the molten mass did not continue. The polymer did not dissol\e in aromatic hydrocarbons. clhorinatcd hydrocarbons. alcohols or ketoncs. and its density. determined pycnometrically. was df" L702).

EXAMPLE 5 A mixture of I grants of l1.].Z-tetrachloroetliyl acrylate. 2 grams of styrene and 0.0] grams of benzoyl peroxide was prepared for polymcri/ation as in E\ample 4. The contents of the ampoulc are polymerized at 60C for 20 hours to a colorless. slightly opalesccnt. elastic plug. The polymer dissol\ ed neither in aromatic nor in chlorinated hydrocarbons and its inllammability was lower than that of pure polystyrene.

EXAMPLE 6 A solution of 3 grams of l.21.Z-tctrachoroethyl acrylate and 0.01] grams of 1.1'-azobisisobutyronitrile in 7 ml of benzene was homo polymerized in a glass dilatometer at a temperature C to about l0 percent conversion of the monomer. After the calculated \olume had been achie ed. the content of the dilatometer was poured into a flask containing 80 ml of ethanol. The colorless polymer precipitated (0.35 grams). and dissolved in benzene as well as in tetrachloromethane.

EXAMPLE 7 A solution of 0.0065 grams of I. 4 azobisisobutyrinitrilc in 5 grams of l.Z.Z.Z-tetracloroethyl methacrylate [the product of Example 3) was prepared for polymerization in the satire way as de scribed in Example 4. After 20 hours of heating at C. a hard plug was formed. The density of the polymer was df" l.60l4. The polymer dissolved in aromatic and chlorinated hydrocarbons and ketones but did not dissolve in aliphatic hydrocarbons. alcohols or in water. It burns in the flame of a gas burner. but when removed from the flame. the molten mass estinguishes.

EXAMPLE 3 A glass ampoule was charged with 7 grams of isoprene. 2 grams of l.12.Z-tetrachloroethyl methacryl ate. 0.05 grams of dodecylmercaptan. 0.04 grams of potassium persulfate. 0.5 grams of -Mersolate'- tweight of a dry substance). and its grants of distilled water. The ampoule was cooled to "78C. macuated. sealed under vacuum and then placed into a container rotating in a water bath at a temperature 5tl(. After 6 hours a latex forms and was poured into 201) ml of ethanol. which had been previously acidified with ()5 ml of concentrated h \drochloric acid. The white pow der precipitated (2.7 grants I, was rubberlikc and solub.e in benzene.

What is claimed is:

I. A l.3.2.ltetraehloroethyl ester compound of the formula wherein X is htdrogen. chlorine or methyl.

2. A compound according to claim 1 wherein X is hydrogen and said compound is l.2.11-tctrachloroethyl acrylatc.

lti

(ill

CH 1 ([I-C-Cl wherein X is selected front the group consisting of hydrogen chlorine or methyl. at a temperature between 20C and (10C for a period ottimc until said compound is formed.

6. A method according to claim 5 wherein said reaction is carried out in the presence of an accelerating agent.

7. A method according to claim 6 wherein said accelerating agent is a mineral acid or a mineral salt.

8. A method according to claim 5 wherein said liquid medium is a non-solvent for the reactants.

9. A method according to claim 6 wherein said reaction is carried out in a liquid medium substantially comprised of said accelerating agent.

ID. The method according to claim 5 wherein the reaction is carried out at ambient pressure. and the resultant mixture is fractionated under a partial vacuum to recover the compound ll. The method according to claim 6. wherein the accelerating agent is selected from the group consisting of mineral acids. salts and organic or inorganic bases.

12. The method according to claim 5, wherein said liquid medium is selected from the group consisting of benzene. diethylether or tetrachloromethane.

13. The method according to claim 5. including the addition of a stabilizer to said mixture. 

1. A 1,2,2,2-TETRACHLOROETHYL ESTER COMPOUND OF THE FORMULA
 2. A compound according to claim 1 wherein X is hydrogen and said compound is 1,2,2,2-tetrachloroethyl acrylate.
 3. A compound according to claim 1 wherein X is methyl and said compound is 1,2,2,2-tetrachloroethyl methacrylate.
 4. A compound according to claim 1 wherein X is chlorine and said compound is 1,2,2,2-tetrachloroethyl-2-chloroacrylate.
 5. A method of preparing a 1,2,2,2-tetrachloroethyl ester compound comprising reacting in a liquid medium a mixture of chloral and acylchloride of the formula
 6. A method according to claim 5 wherein said reaction is carried out in the presence of an accelerating agent.
 7. A method according to claim 6 wherein said accelerating agent is a mineral acid or a mineral salt.
 8. A method according to claim 5 wherein said liquid medium is a non-solvent for the reactants.
 9. A method according to claim 6 wherein said reaction is carried out in a liquid medium substantially comprised of said accelerating agent.
 10. The method according to claim 5 wherein the reaction is carried out at ambient pressure, and the resultant mixture is fractionated under a partial vacuum to recover the compound.
 11. The method according to claim 6, wherein the accelerating agent is selected from the group consisting of mineral acids, salts and organic or inorganic bases.
 12. The method according to claim 5, wherein said liquid medium is selected from the group consisting of benzene, diethylether or tetrachloromethane.
 13. The method according to claim 5, including the addition of a stabilizer to said mixture. 